Smart pump for remotely sending realtime data to a smart device

ABSTRACT

The present invention provides wireless sensor technology seamlessly integrated into a pump system having a pump, a motor and a drive, has diagnostic and prognostic intelligence that utilizes sensor data, allows real-time condition monitoring; enables easy access to data and analytics via smart devices (i.e., smart phones and tablets); allows for easy remote monitoring (i.e., web portal) of the pump system; allows self-learning artificial intelligence (AI) built-in that adapts to changing conditions; and allows for smart pump system remote control. In operation, the present invention monitors the health and performance of the pump system that allows the user to get real-time data and intelligence virtually anywhere and anytime, as well as real-time diagnostics and prognostics, and also allows for smart control of the pump system remotely via smart device, and reduces downtime of equipment.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is related to, and forms part of, a family oftechnologies, e.g., disclosed in the following applications:

-   -   U.S. patent application Ser. No. 14/933,230 (Docket no.        911-002.075/F-GI-1507US), filed 5 Nov. 2015, entitled “Smart        communication device or apparatus for collecting and evaluating        information about equipment distributed over a large area, e.g.,        over a large industrial plant or oil field;”    -   U.S. patent application Ser. No. 14/685,134 (Docket no.        911-002.071/F-GI-1501US), filed 13 Apr. 2015, entitled “Sensing        module for monitoring conditions of a pump or pump assembly;”    -   U.S. patent application Ser. No. 15/456,761 (Docket no.        911-002.068/F-GI-1408US), filed 13 Mar. 2017, entitled “Motor        assembly for driving a pump or rotary device, having a power        plane with multi-later power and control printed circuit board        assembly;”    -   U.S. patent application Ser. No. 14/681,577 (Docket no.        911-002.067/F-GI-1410US), filed 8 Apr. 2015, entitled “Nodal        dynamic data acquisition and dissemination;” and    -   U.S. Pat. No. 8,154,417 (Docket no. 911-002.030-2/F-GI-0706US),        issued 10 Apr. 2012, entitled “Compact self-contained condition        monitoring device;”        which are all incorporated by reference in their entirety.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to a pump system composed of a motor,embedded motor drive, control electronics and software for driving apump; more particularly to a technique for sensing and monitoring such apump system using one or more sensors and associated embedded firmware(F/W) logic.

2. Brief Description of Related Art

In the prior art, wired sensors attached to pump systems to monitor thehealth and performance of the pump system are known. However, theseknown techniques are expensive and complex. The number of sensors islimited due to the expense of wiring and integrating the wiring into thepump system. Viewing the sensor data is also limited to a centralcontrol center (i.e., DCS). Moreover, motor drives are typically mountedremotely in a protected area of the plant which adds complexity andexpense (wiring, etc.). In view of this, there is a need in the industryfor a better way to sense and monitor the health and condition of a pumpsystem.

SUMMARY OF THE INVENTION

In summary, the present invention uses wireless sensor technologyseamlessly integrated into a pump system having a pump, a motor and anembedded motor drive; has diagnostic and prognostic intelligence thatutilizes sensor data; allows real-time condition monitoring; enableseasy access to data and analytics via smart devices (i.e., smart phonesand tablets); allows for easy remote monitoring (i.e., web portal) ofthe pump system; allows self-learning artificial intelligence (AI)built-in that adapts to changing conditions; and allows for smart pumpsystem remote control.

In operation, the present invention monitors the health and performanceof the pump system in a manner that allows the user to get real-timedata and intelligence virtually anywhere and anytime, as well asreal-time diagnostics and prognostics, and also allows for smart controlof the pump system remotely via a smart device, and reduces downtime ofequipment.

The system also contains built-in pump protection in case of a systemfailure protecting the pump from costly damage and repair. Plus, it canoptimize the pump's performance by automatically calculating the bestperformance parameters for the pump system (% BEP). This significantlyreduces operating costs.

Specific Embodiments

According to some embodiments, the present invention may include, ortake the form of, a new and unique apparatus featuring:

a smart device having a signal processor or signal processingcircuit/module configured to:

-   -   receive wireless signaling containing information about sensed        data received from embedded wireless sensor circuit boards        integrated into a pump system having a pump, a motor and a drive        being monitored; and    -   determine corresponding signaling containing information about        real-time health and performance of the pump system being        monitored to allow a user to get real-time sensed data,        intelligence, diagnostics and prognostics remotely via the smart        device, based upon the signaling received.

According to some embodiments of the present invention, the apparatusmay include one or more of the features, as follows:

The signal processor or signal processing circuit/module may beconfigured to provide the corresponding signaling as display signalingfor displaying on a display of the smart device.

The signal processor or signal processing circuit/module may beconfigured to provide the corresponding signaling as control ormonitoring signaling to control or monitor the pump system remotely viathe smart phone.

The embedded wireless sensor circuit boards integrated into the pumpsystem may include one or more of the following:

-   -   one or more seal sensors;    -   one or more oil quality sensors, including for sensing % of        contaminates or fluid level;    -   tri-axial accelerometers;    -   an embedded motor drive;    -   an embedded PumpSmart logic, including for providing pump        control, pump protection or multi-pump control;    -   a suction pressure sensor;    -   a discharge pressure sensor;    -   a pump temperature sensor;    -   a motor temperature sensor, including for providing the        temperature of a motor bearing and motor winding;    -   a wireless communication module,    -   a DC power module;    -   a viscosity sensor;    -   a motor current (Flux) sensor;    -   a pH monitor;    -   a volatile organic compounds (VOC) “sniffing” sensor;    -   a drive shaft phase/position sensor; and/or    -   ‘a network gateway or web portal, for providing LoRaWAN, M2M        communication, Wi-Fi, Low Power Cellular or sub GHz        connectivity.

The apparatus includes, or take the form of, a wirelessmachine-to-machine network, e.g., having the smart device.

The apparatus may include the embedded wireless sensor circuit boards.

The embedded wireless sensor circuit boards may include an electroniccircuit board having at least the following:

-   -   an embedded microcontroller device;    -   an amplifier chip;    -   an electrode connector;    -   a radio chip and    -   an antenna for providing the wireless signaling, and receiving        the corresponding wireless signaling.

The electronic circuit board may be configured to provide seamlessembedded sensor technology, data collection and analysis, web portalaccess and selectable or customizable sensor technology.

The embedded wireless sensor circuit boards may include, or take theform of, a surface mounted device (SMD) made or manufactured usingsurface-mount technology (SMT).

The apparatus may include the surface mounted device (SMD).

The surface mounted device (SMD) may include an integrated sensorconfigured to acquire the sensed data.

The smart device may include, or take the form of, a smart phone, atablet, personal assistance device, a laptop, or a desktop for providingremote access to the real-time health and performance of the pump systembeing monitored and the real-time sensed data, intelligence, diagnosticsand prognostics.

The signal processor or signal processing circuit/module may beconfigured to run or implement an app or application to provide thecorresponding signaling as interrogation wireless signaling containinginformation to request one or more types of sensed data from one or moreof the embedded wireless sensor circuit boards.

Advantages of the present invention include:

-   -   uses inexpensive wireless sensor technology for monitoring a        pump system;    -   easy integration and implementation of the wireless sensor        technology for monitoring a pump system;    -   the ability to use low power sensors for monitoring a pump        system;    -   the ability to view sensor information via a smart phone device        (i.e., a smart phone or tablet); and    -   the elimination of the need for the central control system.

The present invention may also take the form of a method having stepsfor:

-   -   receiving in a smart device having a signal processor or signal        processing circuit/module wireless signaling containing        information about sensed data received from embedded wireless        sensor circuit boards integrated into a pump system having a        pump, a motor and a drive being monitored; and    -   determining with the signal processor or signal processing        circuit/module corresponding signaling containing information        about real-time health and performance of the pump system being        monitored to allow a user to get real-time sensed data,        intelligence, diagnostics and prognostics remotely via the smart        device, based upon the signaling received.        The method may also include steps for implementing one or more        of the features set forth herein.

The present invention provides a better way to monitor the health andperformance of a pump system.

The present invention also has an embedded drive which does not requireany extra wiring or expense to install; instead, it is built into themotor.

BRIEF DESCRIPTION OF THE DRAWING

The drawing includes FIGS. 1-5, which are not necessarily drawn toscale:

FIG. 1 shows a smart device having an app for monitoring a pump inrelation to the cloud and forming part of technology based upon theInternet of Things, according to some embodiments of the presentinvention.

FIG. 2 shows a pump system having a motor for driving a pump, and alsohaving examples of embedded wireless sensor circuit board placements onthe motor and the pump, according to some embodiments of the presentinvention.

FIG. 3 shows a motor for driving a pump having an embedded wirelesssensor circuit board placement, according to some embodiments of thepresent invention.

FIGS. 3A and 3B shows examples of embedded wireless sensor circuitboards like that shown in FIG. 3.

FIG. 4 shows a smart device having an app for monitoring one or morepumps arranged in a wireless machine-to-machine (M2M) network, accordingto some embodiments of the present invention.

FIG. 4A shows an example of a wireless machine-to-machine (M2M) networkand examples of various technologies forming part of the same.

FIG. 5 shows apparatus having a signal processor or processingmodule/circuit, according to some embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION FIG. 1

FIG. 1 shows a smart device 100 having a display 102 with an appgenerally indicated as 104 for monitoring a pump or pump system (FIG. 2)in relation to the cloud C and forming part of overall technology basedupon the Internet of Things IoT. By way of example, FIG. 1 shows thatthe cloud C may be configured to provide cloud services in relation to,e.g., one or more mobile devices, one or more networks, one or moredatabases, one or more servers, one or more apps, and/or one or morewebs. By way of example, the pump or pump system being monitored mayform part of one network on the cloud C. The cloud services may includeexchanging communication signaling, storing and exchanging datasignaling, exchanging control signaling, etc.

By way of example, on the smart device 100 the app 104 may include adashboard 106, e.g., for a pump P101-3, showing readings for variousparameters being sensed and monitored, including a radial reading 106 a,an axial reading 106 b, a horizontal reading 106 c, a temperaturereading 106 d, a runtime reading 106 e and a battery reading 106 f. Theuser can use the dashboard 106 to monitor remotely via the cloud C thereadings for the various parameters being sensed and displayed on thisdashboard. The app 104 may also include one or more other dashboards,e.g., accessed via a dropdown menu 108 for sensing and displaying otherparameters having other readings, parameters, etc.

FIG. 2

FIG. 2 shows a pump system 30 having a pump 32 driven by a motor 34, andalso having examples of placements for associated embedded wirelesssensor circuit boards on the pump 32 and the motor 34, identified asfollows:

1. Seal Sensor (Pump),

2. Oil Quality Sensor (Pump),

-   -   a. % Contaminates (i.e. water & metal debris), and    -   b. Fluid Level, etc.,

3. Tri-Axial Accelerometer (Vibration)—pump,

4. Embedded Motor Drive (Motor),

5. Embedded PumpSmart Logic (Motor),

-   -   a. SmartFlow for controlling the pump's flow,    -   b. Multi-Pump Control, and    -   c. Pump Protection, e.g., including run dry protection, etc.,

6. Suction Pressure sensor (Pump),

7. Discharge Pressure sensor (Pump),

8. Temperature Sensor (Pump),

9. Temperature Sensor (Motor),

-   -   a. Motor Bearings, and    -   b. Motor Windings,

10. Wireless (BLE) Communication Module (Motor),

11. DC Power Module (Motor),

12. Viscosity Sensor (Pump),

13. Motor Current (Flux) Sensor (Motor),

14. pH Monitor (Pump),

15. VOC ‘Sniffing’ Sensor (not shown),

16. Drive Shaft Phase/Position Sensor (Motor),

17. Network Gateway (Web Portal),

-   -   a. LoRaWAN,    -   b. M2M Communication,    -   c. Wi-Fi,    -   d. Low Power Cellular and    -   e. Sub GHz.

The scope of the invention is not intended to be limited to anyparticular placement or placements for the associated embedded wirelesssensor circuit boards; and embodiments are envisioned, and the scope ofthe invention is intended to include, using other placements than thatshown in FIG. 2.

FIGS. 3, 3A and 3B

FIG. 3 shows the motor 34 for driving the pump 32, as well as examplesof features of embedded wireless sensor circuit board shown in FIGS. 3Aand 3B. By way of example, the features may include the following:

-   -   Seamless Embedded Sensor Technology, e.g., using surface mounted        technology (SMT),    -   Pump/Motor Design for Sensor(s) Integration,    -   Integral Power, e.g. for powering the electronics of the motor,    -   Micro-Electronics, e.g. for controlling the motor, as well as        implementing the sensor technology,    -   Secure Wireless Communication, e.g. for providing a        communication link between the embedded wireless sensor circuit        board 20 and the smart device 100,    -   Data Collection and Analysis onboard the embedded wireless        sensor circuit board 20, (It is noted that according to some        embodiments data storage and analytics may take place or be        implemented in the Cloud. Limited memory will be needed and        available within the on-board electronics to store some data to        perform some limited analytics.)    -   Web Portal Access, e.g. for providing a communication link        between the embedded wireless sensor circuit board 20 and a        proprietary website, and    -   Selectable Sensor Technology (Customizable), e.g., for adapting        to customer needs and requests).

By way of example, FIG. 3A shows an embedded wireless sensor circuitboard 20 having an electrode connector 20 a, e.g., for coupling thecircuit board to corresponding electrodes of another circuit board,device or sensor, e.g., including an amplifier chip 20 b (ECG/EMG/EEG)for amplifying signaling associated with the circuit board, an embeddedmicrocontroller device 20 c (with SMD components of the top and bottom)for controlling the circuit board and processing suitable signalingassociated with the circuit board, a radio chip 20 d for processingradio signaling to/from the circuit board, and an antenna 20 e fortransmitting/receiving the radio signaling to/from the circuit board. Byway of example, for each sensor placement like that shown in FIG. 2 theembedded wireless sensor circuit board 20 may be coupled to one or moresensors either via a wireless signal coupling, or via a direct hardwirecoupling.

By way of further example, FIG. 3B shows an embedded wireless sensorcircuit board 20′ having circuits/components 20″, such as the electrodeconnector 20 a, the amplifier chip 20 b, the embedded microcontrollerdevice 20 c, the radio chip 20 d and the antenna 20 e, as well as one ormore embedded sensors 20 f for sensing data, e.g., consistent with thatset forth herein. By way of example, see the different types and kindsof sensors for the placements shown FIG. 2. In this case, the embeddedsensors 20 f may physically form part of the embedded wireless sensorcircuit board 20′.

As one skilled in the art would appreciate, surface-mount technology(SMT) is a method for producing electronic circuits in which thecomponents are mounted or placed directly onto the surface of printedcircuit boards (PCBs). An electronic device so made is called a surfacemounted device (SMD). According to some embodiments, the embeddedwireless sensor circuit boards may take the form of a surface mounteddevice (SMD) produced by, or made using, surface-mount technology (SMT).

The scope of the invention is not intended to be limited to anyparticular feature or features for the associated embedded wirelesssensor circuit boards; and embodiments are envisioned, and the scope ofthe invention is intended to include, using other features than thatshown in FIG. 3A.

FIG. 4

FIG. 4 shows the smart device 100 having an app for monitoring one ormore pumps arranged in a wireless machine-to-machine (M2M) network,according to some embodiments of the present invention.

By way of example, the smart device 100 has an app 114 to scan fordevices displayed on the screen 102 that may include a dashboard 116,showing, e.g., iAlert devices in range, including icons for pump P101-Alabeled 116 a, i-Alert 3 labeled 116 b, i-Alert 2 labeled 116 c, i-Alert1 labeled 116 d, i-Alert 8C 1805 labeled 116 e and a test unit labeled116 f. The user can use the dashboard 116 to monitor remotely via thecloud C the i-Alert device in range for the various parameters beingsensed and displayed on this dashboard. In operation, the user may see awarning displayed on the icon, e.g., such as “vibration, Vib warning”indicating that pump P101-A has a vibration warning. The icons alsoinclude an indication of signal strength using increasingly scaledvertical bars as shown, e.g., where the signal strength for the pumpP101-A shows two bar signal strength, while the signal strength for thei-Alert 3 labeled 116 b is no bars, etc.

The app 114 may also include one or more other dashboards, e.g.,accessed via a dropdown menu 118 for sensing and monitoring otherparameters having other indications, etc.

FIG. 4A shows an example of a wireless machine-to-machine (M2M) networkand examples of various technologies forming part of the same. Accordingto some embodiments, the apparatus according to the present inventionmay be implement as part of such a wireless machine-to-machine (M2M)network.

FIG. 5: The Basic Apparatus 200, Including a Pump System

By way of example, FIG. 5 shows the present invention in the form ofapparatus generally indicated as 200 (see FIGS. 1, 4 and 5) featuring:

the smart device 100 having a signal processor or signal processingcircuit/module 10 a configured to:

-   -   receive wireless signaling containing information about sensed        data received from one or more embedded wireless sensor circuit        boards 20 integrated into a pump system 30 having a pump 32, a        motor 34 and a drive 36 being monitored; and    -   determine corresponding signaling containing information about        real-time health and performance of the pump system 30 being        monitored to allow a user to get real-time sensed data,        intelligence, diagnostics and prognostics remotely via the smart        device 100, based upon the signaling received.

By way of example, the signal processor or signal processingcircuit/module 10 a may be configured to provide the correspondingsignaling as display signaling for displaying on a display of the smartdevice.

By way of further example, the signal processor or signal processingcircuit/module may be configured to provide the corresponding signalingas control or monitoring signaling to control or monitor the pump systemremotely via the smart phone.

By way of example, the functionality of the signal processor 10 a may beimplemented using hardware, software, firmware, or a combinationthereof. In a typical software implementation, the signal processor orsignal processing module 10 a would include one or moremicroprocessor-based architectures having, e. g., at least one processoror microprocessor, random access memory (RAM) and/or read only memory(ROM), input/output devices and control, and data and address busesconnecting the same, and/or at least one input processor and at leastone output processor. A person skilled in the art would be able toprogram such a microcontroller (or microprocessor)-based implementationto perform the functionality described herein without undueexperimentation. The scope of the invention is not intended to belimited to any particular implementation using technology either nowknown or later developed in the future. The scope of the invention isintended to include implementing the functionality of the signalprocessor as stand-alone processor or processor module, as separateprocessor or processor modules, as well as some combination thereof.

By way of example, after reading the instant patent application, oneskilled in the art would appreciate without undue experimentation how toimplement the signal processor 10 a to receive the signaling containinginformation about sensed data received from embedded wireless sensorcircuit boards integrated into a pump system having a pump, a motor anda drive being monitored. The implementation may include the signalprocessor 10 a cooperating, or working in conjunction with, theinput/output module forming part of the other component or circuitryforming part of element 10 b.

By way of further example, after reading the instant patent application,one skilled in the art would appreciate without undue experimentationhow to implement the signal processor 10 a to determine thecorresponding signaling containing information about the real-timehealth and performance of the pump system being monitored to allow auser to get real-time sensed data, intelligence, diagnostics andprognostics remotely via the smart device.

The apparatus 200 may also include one or more other modules,components, etc. generally indicated as 10 b for implementing otherfunctionality associated with the apparatus, but that does not form partof the underlying invention and is not described in detail.

Other ITT Pump Monitoring Technology

By way of example, the present invention may also be used in conjunctionwith other pump monitoring technology, as follows:

-   -   ITT's oil quality sensor technology disclosed in U.S. Pat. Nos.        7,788,973 and 7,814,787;    -   ITT's Embedded PumpSmart logic disclosed in U.S. Pat. Nos.        6,464,464; 6,487,903; 6,564,627; 6,591,697; 6,648,606;        6,776,584; 7,080,508; 7,112,037; 7,746,063; 7,945,411;        8,303,260, which all relate to techniques involving sensor-less        SmartFlow, intelligent multi-pump control, and sensor-less pump        protection;    -   See ITT's Motor assembly for driving a pump or rotary device,        having a power plane with multi-later power and control printed        circuit board assembly, e.g., disclosed in the aforementioned        U.S. patent application Ser. No. 15/456,761 (Docket no.        911-002.068/F-G1-1408US), filed 13 Mar. 2017; and    -   ITT's motor flux sensors disclosed in patent application Ser.        No. 15/648,855 (Docket no. 911-002.087-1/F-GI-1612US), filed 13        Jul. 2017; and patent application Ser. No. 15/648,838 (Docket        no. 911-002.088-1/F-G1-1613US), filed 13 Jul. 2017.

All of the aforementioned patents and patent applications disclosedherein are incorporated herein by reference.

The real-time health and performance of the pump system being monitored,as well as the real-time sensed data, intelligence, diagnostics andprognostics related to the pump system being monitored, may include, ortake the form of, implementations and/or adaptations of theaforementioned pump monitoring technology set forth above, e.g.,including implementations and/or adaptations that form part of signalprocessing performed on or by the embedded wireless sensor circuitboards.

THE SCOPE OF THE INVENTION

It should be understood that, unless stated otherwise herein, any of thefeatures, characteristics, alternatives or modifications describedregarding a particular embodiment herein may also be applied, used, orincorporated with any other embodiment described herein. Also, thedrawings herein are not drawn to scale.

Although the invention has been described and illustrated with respectto exemplary embodiments thereof, the foregoing and various otheradditions and omissions may be made therein and thereto withoutdeparting from the spirit and scope of the present invention.

1.-17. (canceled)
 18. A system for reducing downtime of an apparatus,the system comprising: a module storing a set of instructions which,when processed by at least one processor executing an artificialintelligence algorithm, predicts a fault condition of the apparatusbased on information received from the apparatus; and a transmitter inoperative communication with the apparatus, the transmitter configuredto transmit at least one instruction to the apparatus, for remotelycontrolling the apparatus based on the fault condition predicted by themodule.
 19. The system of claim 18, wherein the apparatus includes atleast one of a pump, a motor, or a drive.
 20. The system of claim 18,wherein the module is part of a smart device selected from the groupconsisting of a smart phone, a tablet, personal assistance device, alaptop, or a desktop.
 21. The system of claim 18, wherein theinformation received from the apparatus is from one or more realsensors.
 22. The system of claim 21, wherein the one or more realsensors include one or more of: an oil quality sensor, including forsensing % of contaminates or fluid level; a tri-axial accelerometer; asuction pressure sensor; a discharge pressure sensor; a pump temperaturesensor; a motor temperature sensor, including for providing thetemperature of a motor bearing and motor winding; a viscosity sensor; amotor current (Flux) sensor; a pH monitor; VOC “sniffing” sensor; or adrive shaft phase/position sensor.
 23. The system of claim 21, whereinthe one or more real sensors is a surface mounted device (SMD) mountedon the apparatus.
 24. The system of claim 21, wherein the one or morereal sensors is integrated into the apparatus.
 25. The system of claim18, the information received from the apparatus is real-time senseddata.
 26. A method for real time condition monitoring of an apparatus,the method comprising: receiving information via a gateway from at leastone sensor mounted on the apparatus; analyzing the received informationto provide real-time condition monitoring of the apparatus; displaying,on a display, information related to the real-time condition monitoringof the apparatus; and transmitting an instruction to the apparatus toremotely control the operation of the apparatus based on the displayedinformation related to the real-time condition monitoring.
 27. Themethod of claim 26, wherein receiving information includes receivinginformation from one or more real sensors.
 28. The method of claim 26,wherein receiving information includes receiving real-time sensed data.29. A computing device comprising a processor configured to executeprogrammable instructions to perform at least the following: receivereal time sensed data from at least one sensor surface mounted on anapparatus; determine, using the real time sensed data, a prognosis ofthe apparatus; and generate a control signal to control the apparatusbased on the determined prognosis, wherein the sensed data is routed viaa gateway connecting the at least one sensor to a cloud of a network,and wherein the sensed data is further routed from the cloud to thecomputing device.
 30. The device of claim 29, wherein the apparatusincludes at least one of a pump, a motor, or a drive.
 31. The device ofclaim 29, wherein the computing device is part of a smart deviceselected from the group consisting of a smart phone, a tablet, personalassistance device, a laptop, and a desktop.
 32. The device of claim 29,wherein the gateway provides LoRaWAN, M2M communication, Wi-Fi, LowPower Cellular or sub GHz connectivity.
 33. The device of claim 29,wherein the programmable instructions are part of an artificialintelligence software platform.